金属夹心CFRP复合材料超声检测方法

新型机翼、弹翼等结构已采用金属夹心碳纤维增强（Carbon Fiber Reinfored Polymer，CFPR）复合材料结构。针对该类复合材料结构的材料组成和结构特点，分析和对比常用的超声穿透法和超声反射法能否对金属夹心CFPR复合材料内部质量进行检测，提出了先采用超声C扫穿透法确定缺陷的平面位置，然后采用高分辨率超声A扫反射法确定复合材料中分层缺陷及采用超声相位法确定复合材料与金属间的脱粘缺陷的方法。采用提出的方法检测带有预置缺陷的试样和实际产品。检测结果表明，提出的方法可准确检测试样中大小为5 mm×5 mm的预置人工分层和脱粘，且能准确检测实际产品中的缺陷。     

碳纤维/树脂基复合材料薄板的超声波检测

针对碳纤维/树脂基复合材料层压板在航空航天运用中的实际特点,分析了碳纤维/树脂基复合材料层压板的缺陷特征,选择纵波垂直反射法作为检测手段,提出了调整探头晶片后面阻尼块的阻尼系数和在探头前面增加软性透射膜水囊结构等改进超声探头的方法,有效地提高探测信号可识别性和减小探测盲区,有利于用反射信号的相位特征及形状来对缺陷进行定性分析.试验表明,改进后的纵波垂直反射法方便实用,操作性强,能有效地对碳纤维/树脂基复合材料层压板进行缺陷检测.     

复合材料空气耦合超声检测

复合材料由于其特殊的物理结构,具有强度高,质量小,力学性能好等优点,广泛应用于航空航天领域.但其在制造过程中会产生夹杂、分层等问题,使复合材料在服役过程中产生安全隐患.针对该问题开发了空气耦合超声检测系统,结合国标HB7224-95与HB5461-90,利用新型的空气耦合超声实现了对10mm以内复合材料分层缺陷的高速准确检测,能在一定程度上反映材料结构.配合一定的图像处理方法使成像精度更高,准确识别3mm以上缺陷部位.结果证明了该检测方法的可靠性,对复合材料生产工艺的改进具有一定的指导意义.     

复合材料层板铺层方式对超声检测结果的影响

对T700/6421炭纤维复合材料在RTM工艺下制作的不同铺层方式的试样,进行两种频率的脉冲反射法超声检测实验,研究纤维铺层方式对超声检测结果的影响,并得到以下结论:纤维铺层方式对声波在材料中传播的声速和衰减有一定影响,在进行缺陷深度定位和材质衰减测量时,应予以修正;纤维铺层方式对复合材料上下表面检测分辨率、层间分层缺陷的可检性和缺陷大小的评定没有明显影响。     

复合材料层板及蜂窝夹层结构的自动喷水超声穿透扫描检测

一、前言 因复合材料的各向异性和制造工艺很难完全的一致性,造成了材料质量上不可避免的离散性,这就给复合材料结构的不连续性的无损检测提出了两项任务:一是能无损地检测复合材料及构件中各类繁多的离散缺陷,以评定力学性能和物理性能的下降程度。二是评价复合材料结构的完整性,以预测构件的安全使用期。因此开展复合材料及构件的无损检测技术,显得尤为重要和迫切。 不同结构不同缺陷的无损检测,国内外开展了多种检测方法研究试验。X射线照相法检测纤维错动、树脂过多过少、夹杂、孔隙等;核磁共振检测固化程度、内部应力等;声谐振检测胶接结构层间脱粘;激光全息照相检测经加载后其应力场的变化能反映到近表面的脱粘,分层等;涡流测量导电纤维铺层方向等;超声波检测复材层板分层、蜂窝夹层结构脱粘等主要缺陷,具有较高的灵敏度和可靠性,而得到广泛的应用。由于超声波脉冲反射法(水浸式、喷水式)、超声波反射板法,其声波在材料中往返穿过二次,且在复合材料结构中声波散射和吸收,声强的高衰减,而使其应用受到限制。喷水穿透法检测,一发一收双探头,声波在材料中只穿过一次,又避开了表面盲区,是适用于复合材料厚层板、板     

纤维增强复合材料制孔分层缺陷检测与评价技术研究进展

纤维增强复合材料的制孔工序是实现复合材料结构件连接的重要环节,复合材料的各向异性和层间强度低极易导致分层缺陷,而制孔质量直接影响复合材料零部件物理性能的发挥和安全服役中的可靠性。因此,必须对复合材料制孔的分层缺陷进行检测并加以评价,用以优化刀具设计和加工工艺参数。该文在简要阐述制孔分层缺陷产生机理的基础上,首先,重点分析渗透液、光学、渗透X射线、常规超声C扫描、工业CT和超声显微镜6种分层缺陷检测方法的基本原理、特点及研究进展;然后,分类总结制孔分层缺陷的7种定量评价因子;最后,讨论复合材料制孔缺陷在线监测与评价的可行性和所面临的技术挑战。     

复合材料层压板分层缺陷相控阵超声检测参数优化方法EI北大核心CSCD

针对复合材料层压板分层缺陷的准确识别问题,通过仿真与实验提出相控阵超声检测激活孔径优化方法,研究并分析不同聚焦深度下激活孔径对声场特性和检测效果的影响。首先,针对相控阵超声接触式检测方法,推导出固固界面下的多点源三维声场模型;然后,对相控阵超声声场进行仿真,研究不同激活孔径下的声场特性;最后,采用热压工艺制备含分层缺陷的碳纤维增强树脂基复合材料(CFRP)层压板,并搭建相控阵超声检测系统对其进行检测。实验结果表明,通过对相控阵超声激活孔径进行优化选择,能够实现CFRP层压板分层缺陷的准确识别,有效提高缺陷检测精度。     

陶瓷及陶瓷基复合材料微缺陷的超声检测

为研究陶瓷及陶瓷基复合材料微缺陷的超声检测能力，针对一些人工缺陷试样进行了超声检测试验。试验主要采用了纵波垂直入射法和泄漏瑞利波法。通过试验结果，比较了两种方法的检测能力。     

超声波技术在现代战机复合材料结构损伤缺陷检测中的应用

文章论述了现代战机机体上复合材料胶接结构的超声检测技术.该技术以声阻法为原理,对相应的超声检测系统进行了设计.据此系统可以检测复合材料脱粘伤等缺陷形式,并且可以定性评估缺陷损伤程度.在实际应用中,已经验证了该方法的可行性、可靠性和准确性.     

混凝土分层缺陷的超声检测方法研究

为解决混凝土结构中分层缺陷的在线非接触检测难题,论文提出了利用空气耦合(简称:空耦)超声导波定量检测混凝土结构中分层缺陷的新方法。首先研究了空耦超声导波在混凝土结构中的传播特性,理论分析和实验表明,利用空耦超声波以入射角8.7°入射厚度为50 mm的混凝土板时,可以激发以A0模态为主的导波。然后构建了空耦超声导波扫查实验系统,在混凝土结构单侧利用一对倾斜8.7°的空耦探头激励和接收导波信号,通过分析发现A0模态对分层缺陷敏感,且其幅度与扫查路径中的分层缺陷尺寸存在单调变化关系;在此基础上,对检测区域进行扫查,利用不同位置处的导波信号幅度实现分层缺陷的二维成像。实验结果表明,该方法不仅可以避免耦合剂对检测结果的影响,同时可实现对服役状态下混凝土结构中分层位置及尺寸的定量检测。     

复合材料层压板分层缺陷超声相控阵检测与评估

针对碳纤维增强树脂基复合材料分层缺陷的无损检测与评估问题,通过制备预埋分层缺陷的标准试样,利用超声相控阵技术对缺陷进行无损检测与定量评估,并对测量误差进行分析。首先,在层压板铺层中间埋入聚酰亚胺薄膜制备分层缺陷试样;然后,对试样进行超声相控阵检测,通过超声S扫和C扫图像对缺陷进行定性分析与定量测量,并结合声场仿真对检测误差进行分析。结果表明:所制备试样内分层缺陷形状规则、埋深及大小与预设一致;超声相控阵步进方向检测尺寸比较准确,而扫查方向尺寸误差较大;超声相控阵技术能够准确识别分层缺陷的形状、尺寸及位置,具有很高的检测精度,对较小缺陷具有很好的检测效果。     

基于超声能量扩散的CFST界面剥离损伤检测方法与验证

钢管混凝土(CFST)构件因其具有良好的抗压、抗弯、抗剪能力,近年来被广泛用于各类型工程结构之中。鉴于CFST施工过程中,钢管与内部混凝土之间可能出现离析、剥离等缺陷,会降低或破坏钢管与混凝土的协同作用,导致承载力降低等问题。在受到极端荷载下,严重时会导致较大安全隐患和失效可能。因此,开展CFST剥离损伤检测十分必要。该文试制了采用超声能量扩散进行构件损伤检测的测试平台;对一批预设界面剥离损伤的方形截面CFST柱进行了不同频率超声波、考虑不同剥离尺寸影响的实测研究,得到归一化扩散及耗散系数,并以此作为管壁与内部混凝土剥离的检测指标;基于最佳激发频率提出CFST界面损伤判定依据,并采用COMSOL软件进行数值模拟验证。结果表明：归一化扩散及耗散系数对剥离损伤尺寸较敏感,可作为探明损伤规律性的重要参数。提出的CFST界面损伤判定模型与仿真试验吻合良好,最小误差为3.03%,平均误差小于10%,表明损伤判定模型能准确、有效定量识别钢管与核心混凝土间的界面剥离损伤,可拓展应用于同类型构件的损伤诊断和预判。     

Investigation of laser pulse fatigue effect on unpainted and painted CFRP structures

Laser ultrasonic based nondestructive evaluation (NDE) techniques are being increasingly used in aerospace industries. Generally, the service lifetime for an aircraft could be more than 25 years. Thus, the composite structures of the aircraft could be susceptible to laser pulse fatigue damage caused by the laser pulse energy in the long-term repetitive maintenance inspection. In this paper, the effect of repeat laser pulse scanning on the mechanical characteristics of unpainted and painted CFRP specimens (USN175BX Carbon UD prepreg, Bisphenol A epoxy resin) is investigated to verify the reliability regarding the use of laser ultrasonic scanning based NDE techniques on the inspection of the CFRP structure. A high-speed laser ultrasonic scanning system is setup to perform repeat scanning of 1300 times on both CFRP specimens at the five laser pulse energy levels using the 532-nm and 1064-nm Q-switched continuous wave lasers. Elastic modulus assessment based on the ultrasonic Lamb wave pitch–catch method is used and the surface condition of the scanned area is investigated by a microscope. As a result, the laser pulse fluences that is shown in this paper are suitable for the long-term repetitive maintenance inspection in unpainted and painted CFRP structure even if it demonstrates an embrittlement phenomenon similar to the modulus measurement resolution in the unpainted CFRP specimen. In addition, the laser pulse fluence for maximum signal-to-noise ratio without any damage is investigated in both unpainted and painted CFRP specimens. As a result, both 102.45 mJ/cm² in unpainted CFRP specimen and 51 mJ/cm² in painted CFRP specimen can be the laser pulse energy for the maximum signal-to-noise ratio without any damage.     

Signal Quality Improvement Using a New TMSSE Algorithm: Application in Delamination Detection in Composite Materials

This paper introduces a novel method to improve the quality of ultrasonic phased array signals for localizing with accuracy delamination defects. The improvement is achieved by the introduction of a new threshold for the Shannon energy. In first, we have applied the threshold modified S-transform algorithm (TMST) in the case of ultrasound B-scan. Thereafter, we have adapted and applied the S-transform Shannon energy (SSE) algorithm in the field of ultrasonic testing. At last, we have proposed a novel algorithm based on threshold modified S-transform and Shannon energy (TMSSE) to increase the improvement of the ultrasound B-scan. A simulation study has been carried out simulating a composite material containing three defects in different positions in order to highlight the phenomenon of delamination. Experimental tests were performed on a sample of carbon fiber reinforced polymer composite material (CFRP) with a delamination defect close to the front face. Both experimental and simulated results show that the proposed method can improve the quality of ultrasound B-scan which enhances the localization of delamination defects.     

Nondestructive Porosity Assessment of CFRP Composites with Spectral Analysis of Backscattered Laser-Induced Ultrasonic Pulses

The laser-ultrasonic method for nondestructive quantitative local porosity assessment for CFRP composites is proposed and realized experimentally for only one available flat surface of a specimen or a product. This method combines the laser thermoelastic generation and the high-sensitivity piezoelectric detection of broadband pulses of longitudinal ultrasonic waves and does not require the detection of the backwall echo ultrasonic signal. The generation and the detection of ultrasonic pulses is carried out with the specially designed laser-ultrasonic transducer, which allows one to obtain both the temporal profile and the frequency spectrum of a part of the ultrasonic signal backscattered by gas voids in a composite specimen. The frequency spectrum of backscattered ultrasonic pulses is analyzed for three sets of CFRP specimens with different epoxy matrix fractions and porosity. The empirical relation between porosity of CFRP specimens and the spectral power (structural noise power) of ultrasonic signals backscattered by voids is obtained for porosity values up to 0.15. This relation allows one to evaluate the local porosity from measured structural noise power both for CFRP specimens and products fabricated from the same composite material. The proposed laser-ultrasonic setup demonstrates a basis for a system of CFRP porosity assessment in field conditions. It can be very useful especially for nondestructive detection of structural changes of composite materials that will allow evaluation of products during their life time.     

不同编织角碳纤维增强聚合物复合材料-Al方管的吸能特性

为了提高薄壁结构的比吸能,通过环形编制技术制备不同编织角度的碳纤维增强聚合物复合材料-铝（CFRP-Al）方管。对不同编织角度、管长和管厚的CFRP-Al方管进行准静态轴向压缩试验,研究CFRP复合材料编织角度对CFRP-Al方管变形模式和比吸能的影响。结果表明,CFRP复合材料可以降低薄壁管的柔度,从而阻止整体欧拉失稳变形模式;大编织角度CFRP复合材料可以有效承担因薄壁管折叠产生的横向拉力,从而阻止薄壁管折角撕裂;此外,随着编织角度增加,CFRP-Al方管的比吸能随之增大。      

Finite element analysis of an inelastic interface in ultrasonic welded metal/fibre-reinforced polymer joints

The ultrasonic welding technology is an innovative method to produce hybrid joints for multi-material components. In this contribution, the behaviour of an interface layer of metal/fibre-reinforced polymer single overlap tensile specimens is considered. The investigations are carried out using the ultrasonic metal welding technique (UMW) for joining carbon fibre reinforced thermoplastic composites (CFRP) with aluminium alloys. An interfacial traction-separation-law based on elastoplasticity with Lemaitre-type damage is applied. The finite element method is used for the analysis of damage evolution. Two-dimensional interface elements are employed for modelling the solid interface in a 3-D problem. Numerical simulations are carried out for three different interface geometries: square, elongated rectangle and cross rectangle. It is shown that damage develops slower in the specimen with square interface than in the specimen with rectangle interface. The damage parameter reaches the maximum value in every loadstep in the specimen with cross-rectangle interface. Comparison with experimental data shows that the damage process and the fractured zone are identical to simulated results for the specimen with square interface.     

Al/CFRP混合薄壁结构耐撞性能可靠性优化设计

轻量化是实现汽车产业向安全、节能、环保发展的一个重要途径。Al/CFRP（carbon fiber reinforced plastic，碳纤维增强复合材料）混合材料能够在提升轻量化效果的同时兼顾材料成本和结构耐撞性能。为探索方形截面Al/CFRP混合薄壁结构的最佳组合方式，首先，制备了Al方管、CFRP方管和Al/CFRP混合方管，并开展准静态压溃实验。然后，建立能够精确模拟Al/CFRP混合方管压溃响应的有限元模型。最后，将试验设计方法、代理模型技术、多目标优化算法和蒙特卡罗模拟技术相结合，对Al/CFRP混合方管分别进行多目标确定性与可靠性优化设计，并对效果较好的可靠性优化解进行仿真验证。准静态压溃实验结果表明，Al/CFRP混合方管具有优异的耐撞性能；优化结果表明，可靠性优化解的约束可靠度相比于确定性优化解提高了10.96%，大大降低了失效概率，具有更强的实用性。研究结果有望对Al/CFRP混合薄壁吸能构件的优化设计提供参考。